Description

This dock was created as a birthday present for my little bro and is basically a mixture of my favorite aspects from a few existing designs I liked. It's been printed/tested and it fits an iPhone 4 with or without a case (as long as the case is less than 2mm thick).

Main features:

Nice and heavy (weighted with BB's) so just one hand is needed to remove the iPhone and the dock doesn't lift off the desk/table.

Quick release sound amplification tubes can be attached to allow for easy to hear speaker/video chat while docked. They're also pretty decent for amplifying music.

Will fit iPhones with or without cases - you just have to choose the correct length connector stop piece.

Making this requires using a soldering iron to weld/melt threaded inserts into the bottom holes of the Dock Body part. If you don't know how install threaded inserts it's super easy - look here for instructions: thingiverse.com/thing:30576

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Instructions

The PDF drawing attached has the Bill of Materials and an exploded view of the assembly showing all item locations and orientations. I think the assembly process is pretty self-explanatory once you see the drawing. If there are any questions or if I missed something feel free to let me know :)

All the STL's are in the first zip file.

There are 2 different 'Amp Tube' lengths and the long ones produce a slightly louder sound.

There are 4 different length versions of the 'Connector Stop' part and the one you need depends on whether you're using one of the shorter connectors or longer connectors, as well as on whther or not your phone has a case. In order for the 'Amplification Tubes' to work optimally your iPhone needs to rest right on top of the speaker hole, so test the Connector Stop that seems best and if the connector protrudes too much then use a shorter one.

The Rubber Pad is something I had lying around and I'm not sure where it came from. I think you can probably find a suitable thin rubber sheet material at a hardware or craft store. Or just use some rubber feet. A DXF of the pad outline I used is attached and I cut mine with a pair of scissors.

You can buy the BB's to fill the reservoir at a sporting goods store.

My parts were printed in PLA with a .5mm nozzle and .15mm layers, 40% hexagonal infill for the Dock Body and 100% infill for the rest of the pieces.

The second ZIP file contains a pack-and-go of all the Solidworks 2012 files including the drawing.

I've printed a lot of docks. This one is my favorite by far. It reminds me of the Elevation dock.

I printed two of these on the Replicator 2 using the default Makerware settings and they came out perfect. I weighed them down with rolls of pennies. I would have used BB's but I wanted to take the docks in my carry-on through the airport.

If I get can find the time, I'd like to make a derivative for the iPhone 5 with compartments specifically for rolls of pennies.